Automatic print speed control for indicia printer

ABSTRACT

A label printing device and method include a proportional-integral-derivative controller and a variable speed printer motor. The variable speed printer motor is connected to the proportion-integral-derivative controller, and has an automatically optimized printing speed determined by a print duration history of one or more previously completed print jobs.

FIELD OF THE INVENTION

The invention is generally related to indicia printers, and, morespecifically, to indicia printers having automatic print speed control.

BACKGROUND

Decodable indicia are graphical representations of data, the most commonof which are one dimensional (1D) and two dimensional (2D) barcodes. 1Dbarcodes are images that represent data by varying the widths andspacing of parallel lines. 2D barcodes are also images that representdata, but in addition to the parallel lines or bars, 2D barcodes canfurther include rectangles, dots, hexagons and other geometric patternsin two dimensions.

Decodable indicia are commonly printed on labels by indicia printers,which operate at relatively high printing speeds. Certain types ofindicia print jobs, such as the more complicated 2D barcodes, requirelonger times to send to a printer and/or being processed by acorresponding printer language interpreter, than the time actuallyrequired to feed and print the label. As shown for example in FIG. 4,when these types of print jobs are sent in sequence to the indiciaprinter, frequently the indicia printer will decelerate and sometimesstop between printing each label as the indicia printer waits from theprinter language interpreter to receiving and process the next printjob. Frequent deceleration and stops renders lower print precision, anuneven noise environment, and wear and tear on indicia printer parts,such as a print motor.

SUMMARY

In one aspect, the invention embraces a method for printing a labelusing a variable speed printer that optimizes a printing speed of thevariable speed printer through a proportional-integral-derivativecontroller for a new print job based on a print processing durationhistory of one or more previously completed print jobs; andautomatically adjusts the printing speed based on the optimized printingspeed.

In an embodiment, the print duration is a length of time extending froman actuation of a print job to a completion of the print job.

In an embodiment, optimizing the printing speed includes storing theprint duration and print processing duration history of one or morepreviously completed print jobs.

In another embodiment, optimizing the printing speed includes capturingand storing a first time stamp of when a new print job is actuated.

In yet another embodiment, optimizing the printing speed includescalculating a theoretical print duration of the new print job startingfrom the first time stamp, by determining a print duration ratio of aprint media length to a current printing speed.

In another embodiment, optimizing the printing speed includes storing asecond time stamp of when a subsequent print job is queued.

In another embodiment, optimizing the printing speed includescalculating a difference between the theoretical print duration of thenew print job and a print processing duration of one or more of thepreviously completed print jobs to produce an error value.

In an embodiment, when the error value is positive, theproportional-integral-derivative controller automatically decreases theprinting speed of the variable printer to adjust the error value toapproximately zero.

In an embodiment, when the error value is negative, theproportional-integral-derivative controller automatically increases theprinting speed of the variable printer to adjust the error value toapproximately zero.

In another embodiment, the print duration of the new print job isapproximately equal to or greater than a print processing duration for asubsequent print job.

In yet another embodiment, the print processing duration is a length oftime extending from an input of the subsequent print job into the queueto an output of the subsequent print job to the variable speed printer.

In an embodiment, the variable speed printer is a barcode printer.

In an embodiment, the print duration history is an average of printdurations for two or more previously completed print jobs.

In another aspect, the invention embraces a barcode label printingdevice having a proportional-integral-derivative controller; and avariable speed printer motor connected to theproportion-integral-derivative controller, and having an automaticallyoptimized printing speed determined by a print duration and a printprocessing duration history of one or more previously completed printjobs.

In an embodiment, the barcode label printing device includes a markersystem connected to the variable speed printer and having a thermalprint head.

In an embodiment, the print duration is a length of time extending froman actuation of a print job to a completion of the print job.

In another embodiment, the optimized printing speed is a differentbetween a theoretical print duration of a current print job and theprint processing duration history.

In an embodiment, the theoretical print duration of the new print job isa print duration ration of a print media length to a current printingspeed.

In another embodiment, when the difference between the theoretical printduration and the print processing duration is negative, the optimizedprinting speed is higher than when the difference is positive.

In yet another embodiment, the print duration of the current print jobis approximately equal to or greater than a print processing duration ofa subsequently queued print job.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example, with reference tothe accompanying Figures, of which:

FIG. 1 is a perspective view of an indicia label printing device;

FIG. 2 is a schematic diagram of a control feedback system using aproportion-integral-derivative controller;

FIG. 3 is a diagram of a data processing device;

FIG. 4 is a diagram showing printing speed of a variable speed printermotor when a print processing time exceeds a label print time;

FIG. 5 is a diagram showing a proportional-integral-derivativecontroller optimized printing speed of the variable speed printer motorwhen print processing time is equal to the label print time; and

FIG. 6 is a block diagram of a method of optimizing printing speed usingthe proportional-integral-derivative controller.

DETAILED DESCRIPTION

In an embodiment shown in FIG. 1, an indicia label printing device 1includes a proportional-integral-derivative controller 11 (“PIDcontroller”), a variable speed printer motor 12, a marker system 13, andprint media 14 having labels 14 a. In an embodiment, the indicial labelprinting device 1 is a barcode printer.

As shown in an embodiment of FIG. 1, the variable speed printer motor 23is connected to the PID controller 11, which operates as a closedcontrol loop feedback mechanism that automatically optimizes a printingspeed of the variable speed printer motor 23 using a print processingduration Dn history of one or more previously completed print jobs. Seealso, FIG. 2 for a control feedback system 300 utilized by the PIDcontroller 11.

As shown in an embodiment of FIG. 1, the marker system 13 is connectedto the variable speed printer motor 12 and includes a thermal print head12 a.

The indicia label printing device 1 is connected to a computing device500. In an embodiment shown in FIG. 3, the computing device 500,includes one or more of a processing unit 502, memory 503, removablestorage 510, and non-removable storage 512. The computing device 500 canbe a computer, a laptop, a tablet, or other computing device includingthe same or similar elements as illustrated and described with regard toFIG. 3. Although the various data storage elements are illustrated aspart of the computer 500, the storage may also or alternatively includecloud-based storage accessible via a network, such as the Internet.

Memory 503 can include volatile memory 514 and non-volatile memory 508.Computer 500 may include—or have access to a computing environment thatincludes—a variety of computer-readable media, such as volatile memory514 and non-volatile memory 508, removable storage 510 and non-removablestorage 512. Computer storage includes random access memory (RAM), readonly memory (ROM), erasable programmable read-only memory (EPROM) &electrically erasable programmable read-only memory (EEPROM), flashmemory or other memory technologies, compact disc read-only memory (CDROM), Digital Versatile Disks (DVD) or other optical disk storage,magnetic cassettes, magnetic tape, magnetic disk storage or othermagnetic storage devices, or any other medium capable of storingcomputer-readable instructions known to those of ordinary skill in theart.

In another embodiment shown in FIG. 5, the computer 500 can include orhave access to a computing environment that has an input 506, output504, and a communication connection 516. Output 504 includes a displaydevice, such as a touchscreen, that also may serve as an input device.The input 506 can include one or more of a touchscreen, touchpad, mouse,keyboard, camera, one or more device-specific buttons, one or moresensors integrated within or coupled via wired or wireless dataconnections to the computer 500, and other input devices. In anembodiment, the computer 500 can operate in a networked environmentusing a communication connection to connect to one or more remotecomputers (not shown), such as database servers. The remote computer canbe a personal computer (PC), server, router, network PC, a peer deviceor other common network node, or the like commonly known to those ofordinary skill in the art. The communication connection can be a LocalArea Network (LAN), a Wide Area Network (WAN), cellular, WiFi,Bluetooth, or other commonly known networks.

Computer-readable instructions stored on a computer-readable medium areexecutable by the processing unit 502 of the computer 500. A hard drive,CD-ROM, and RAM are examples of articles, including a non-transitorycomputer-readable medium like a storage device. The terms“computer-readable medium” and “storage device” generally excludescarrier waves. For example, a computer program 518 capable of providinga generic technique to perform access control check for data accessand/or for doing an operation on one of the servers in a componentobject model (COM) based system can be included on a CD-ROM and loadedfrom the CD-ROM to a hard drive. The computer-readable instructionsallow computer 500 to provide generic access controls in a COM basedcomputer network system having multiple users and servers.

Those of ordinary skill in the art would appreciate that PIDcontrollers, in general, attempt to correct errors in a system between ameasured process variable and a desired setpoint, by calculating andthen outputting a corrective action that adjusts the process accordinglyand rapidly, in order to minimize error over time. To accomplish this,the PID controller algorithm includes coefficients for proportional (P,K_(P)), integral (I, K_(i)), and derivative (D, K_(d)) terms, where Paccounts for present values of error, I accounts for past values oferror, and D accounts for predicted future values of error based oncurrent rates of change. In the embodiments shown in FIGS. 1-6, the PIDController 11 operates as a closed control loop feedback mechanism thatautomatically optimizes (i.e., determines and/or adjusts) a printingspeed of the variable speed printer motor 23 using the print processingduration Dn history of one or more previously completed print jobs.

In a general embodiment, processor 502 captures and stores a first timestamp Tn of a print job n being actuated in memory 503. Specifically,processor 502 captures the first time stamp Tn at a moment whenprocessing (parsing, rendering) of the print job is complete and thesystem is ready to actuate the variable speed printer motor 23.Processor 502 also determines whether a subsequent print job is in queueby flagging Fn the subsequent print job. Processor 502 sends first timestamp Tn and flag Fn to memory 503 for storage. Processor 502 calculatesa total processing (parsing, rendering) time from a previous time stampTn−1 to first time stamp Tn to create a history of time stamps thatcorrelate approximately with processing (parsing, rendering) timerequired for processor 502 to process new print job n. Processor 502sends the historical processing (parsing, rendering) and theoreticalprinting duration information to the PID controller 11, which thencalculates an error E value determined by comparing a theoreticalprinting duration N to the processing (parsing, rendering) time. The PIDcontroller 11 automatically adjusts the current print speed S tominimize any deceleration or acceleration of the variable speed printingmotor 12 by minimizing the error E value between theoretical printduration N and an actual print processing (parsing, rendering) durationDn.

In an embodiment, a process of optimizing a printing speed of thevariable speed printing motor 2 by minimizing printing speed error isdescribed as follows:

  1. Print job n is actuated; 2. Processor 502 stores first time stampTn of when print job n is parsed, rendered and ready to be actuated, andstores flag Fn indicating whether a subsequent print job is in queue inmemory 503; 3. If Fn-1 is true then  a. print processing (rendering,parsing) duration Dn between previous time stamp Tn-1 of a completedprint job and the first time stamp Tn is calculated Dn = Tn − Tn-1; and b. use the PID controller 11 to:   calculate theoretical print durationN based on print speed S of  the variable speed printing motor 12 andmedia length L where  N = L/S,   calculate error E, where E = N − Dn,  adjust the error E with offset K, to make the PID controller 11  tryto increase print speed, where error E is equal to E + K, and  determine and set a new, optimized print speed S_(N).

Thus, the print processing duration Dn is a length of time extendingfrom an actuation of a print job n to a completion of the print job n;the optimized printing speed S_(N) is a difference between a theoreticalprint duration N of a new print job n and the print processing durationDn of a previous print job; and the theoretical print duration N of anew print job is a print duration ratio of a print media length L to acurrent printing speed S. In an embodiment, the print processingduration Dn history is the print processing durations Dn for two or morepreviously completed print jobs. In another embodiment, the printprocessing duration Dn is an average of print processing durations Dnfor two or more previously completed print jobs.

In an embodiment, when the difference between the theoretical printduration N and the print processing duration Dn history of previousprint jobs is negative, the optimized printing speed is higher than whenthe difference between the theoretical print duration N and the actualprint processing duration Dn is positive.

In an embodiment, when the error E between the theoretical printduration N and the actual print processing duration Dn is positive, thePID controller 11 automatically decreases the printing speed of thevariable speed printer motor 23 to adjust the error E to approximatelyzero. Conversely, when the error value is negative between thetheoretical print duration N and the actual print processing duration Dnis positive, the PID controller 11 automatically increases the printingspeed S of the variable speed printer motor 23 to adjust the error E toapproximately zero. In an embodiment, the print processing duration Dnof a print job n is approximately equal to or greater than a printprocessing duration Dn of a subsequently queued print job n by processor502 once the PID controller 11 has determined and set the new, optimizedprint speed S_(N).

As shown in FIG. 5, after the PID controller 11 has adjusted the printspeed S of the variable speed printer motor 23 to the optimized printspeed S_(N), the actual print processing duration Dn of the print job nis approximately equal to or greater than a print processing duration Dnfor a subsequent print job. The print processing duration Dn is a lengthof time extending from an input of the subsequent print job into thequeue to an output of the subsequent print job to the variable speedprinter motor 23. Thus, as shown in FIG. 5 and in contrast to FIG. 4,when the variable speed printer motor 23 is operating at the optimizedprinting speed S_(N), the variable speed printer motor 23 seamlesslyfinishes printing Label #1 and transitions to printing Label #2 withouthaving to accelerate or decelerate.

In an embodiment shown in FIG. 6, a method for printing a label using avariable speed printer, includes the steps of providing a indicia labelprinting device 1 having a PID controller 11 at block 200; connectingthe indicia label printing device 1 to the computing device 500 at block201; storing the print processing duration Dn history of one or morepreviously completed print jobs in memory 503 at block 202; capturingwith processor 502 and storing in memory 503 a first time stamp Tn ofwhen a new print job n is actuated at block 203; calculating withprocessor 502 a theoretical print duration N of the new print job nstarting from the first time stamp Tn, by determining a theoreticalprint duration N ratio of a print media length L to a current printingspeed S at block 204; storing a flag Fn of when a subsequent print jobis queued at block 205; calculating a difference between the theoreticalprint duration N of the subsequent print job and an actual printprocessing duration Dn based on a previously completed print job toproduce an error value E at block 206; optimizing a printing speed S ofthe variable speed printer motor 11 through the PID controller 11 basedon a print processing duration Dn history of the completed print job ora print processing duration Dn history calculated from an average printprocessing duration Dn of two or more previously completed print jobs nat block 207; and automatically adjusting the printing speed S of thevariable speed printer motor 11 based on the optimized printing speedS_(N) for the subsequent print job, such that the actual print durationN of the new print job n is equal to or greater than the printprocessing duration Dn of the subsequently queued print job at block208.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The invention is not limited to suchexemplary embodiments. The use of the term “and/or” includes any and allcombinations of one or more of the associated listed items. The figuresare schematic representations and so are not necessarily drawn to scale.Unless otherwise noted, specific terms have been used in a generic anddescriptive sense and not for purposes of limitation. The use of theterms “first,” “second,” “third,” etc. are used as labels, and are notintended to impose numerical requirements upon their subjects, unlessclearly stated. Furthermore, references to “an embodiment” or “anotherembodiment” are not intended to be interpreted as excluding theexistence of additional embodiments that also incorporate the recitedfeatures. Moreover, unless explicitly stated otherwise, embodiments“comprising,” “including,” or “having” an element or plurality ofelements having a particular property may include additional elementsnot having that property.

What is claimed is:
 1. A method for printing a label using a variablespeed printer, comprising the steps of: optimizing a printing speed ofthe variable speed printer through a proportional-integral-derivativecontroller for a new print job based on a print duration and printprocessing duration history of one or more previously completed printjobs, such that an actual print duration of the new print job is equalto or greater than a print processing duration of a queued print job;and automatically adjusting the printing speed based on the optimizedprinting speed, the variable speed printer executing the new print jobat the optimized printing speed and transitioning to printing thesubsequently queued print job without having to increase or decrease theprinting speed.
 2. The method of claim 1, wherein the print duration isa length of time extending from an actuation of a print job to acompletion of the print job.
 3. The method of claim 2, whereinoptimizing the printing speed includes the step of storing the printduration and print processing duration history of one or more previouslycompleted print jobs.
 4. The method of claim 3, wherein optimizing theprinting speed further includes the step of capturing and storing afirst time stamp of when a new print job is actuated.
 5. The method ofclaim 4, wherein optimizing the printing speed further includes the stepof calculating a theoretical print duration of the new print jobstarting from the first time stamp, by determining a print durationratio of a print media length to a current printing speed.
 6. The methodof claim 5, wherein optimizing the printing speed further includes thestep of storing a second time stamp of when a subsequent print job isqueued.
 7. The method of claim 6, wherein optimizing the printing speedfurther includes the step of calculating a difference between thetheoretical print duration of the new print job and a print processingduration of one or more of the previously completed print jobs toproduce an error value.
 8. The method of claim 7, wherein when the errorvalue is positive, the proportional-integral-derivative controllerautomatically decreases the printing speed of the variable printer toadjust the error value to approximately zero.
 9. The method of claim 8,wherein when the error value is negative, theproportional-integral-derivative controller automatically increases theprinting speed of the variable printer to adjust the error value toapproximately zero.
 10. The method of claim 9, wherein the printduration of the new print job is approximately equal to or greater thana print processing duration for a subsequent print job.
 11. The methodof claim 10, wherein the print processing duration is a length of timeextending from an input of the subsequent print job into the queue to anoutput of the subsequent print job to the variable speed printer. 12.The method of claim 8, wherein the variable speed printer is a barcodeprinter.
 13. The method of claim 7, wherein the print duration historyis an average of print durations for two or more previously completedprint jobs.
 14. A barcode label printing device comprising: aproportional-integral-derivative controller; and a variable speedprinter motor connected to the proportion-integral-derivativecontroller, and having an automatically optimized printing speeddetermined by a print duration and a print processing duration historyof one or more previously completed print jobs, such that an actualprint duration of a new print job is equal to or greater than a printprocessing duration of a queued print job, and the new print job isperformed at the optimized printing speed and transitions to printingthe subsequently queued print job without having to increase or decreasethe printing speed.
 15. The barcode label printing device of claim 14,further comprising a marker system connected to the variable speedprinter and having a thermal print head.
 16. The barcode label printingdevice of claim 14, wherein the print duration is a length of timeextending from an actuation of a print job to a completion of the printjob.
 17. The barcode label printing device of claim 16, wherein theoptimized printing speed is a different between a theoretical printduration of a current print job and a print processing duration.
 18. Thebarcode label printing device of claim 17, wherein the theoretical printduration of the current print job is a print duration ratio of a printmedia length to a current printing speed.
 19. The barcode label printingdevice of claim 18, wherein when the difference between the theoreticalprint duration and the print processing duration is negative, theoptimized printing speed is higher than when the difference is positive.20. The barcode label printing device of claim 19, wherein the printduration of the current print job is approximately equal to or greaterthan a print processing duration of a subsequently queued print job.